Custom scooter chassis: When the original machine is no longer enough
Preparing an electric scooter involves enhancing an existing platform. However, there comes a point where the platform itself becomes the limiting factor: insufficient space for the battery, a geometry designed for urban use, and a frame and suspension not engineered for the demands of high performance. A custom chassis, on the other hand, starts from a blank slate, built around the chosen components and the rider's needs. This is the path that the RM-X, our record-breaking machine, followed.
The essentials
- The chassis refers to the structure: the deck, the steering column, the arms, and the mounting points for the suspension and brakes.
- We move on to custom solutions when the original space, geometry, or rigidity prevents the desired modifications.
- The chassis is designed to encompass and integrate the various components: battery, motors, controllers, and brakes.
- The RM-X, a chassis designed and manufactured in Lyon, has reached a speed of 173 km/h, as measured on a test track.
Signs that you are reaching the end of the original battery's lifespan
On a highly optimized setup, several limitations start to emerge one after another:
- Placement: The desired battery doesn't fit, and the controllers end up being mounted externally
- Geometry: The steering angle, wheelbase, and height are designed for everyday use, not for racing
- Stiffness: The column, the folding mechanism, and the arms all experience stress during braking and acceleration
- Mounting points: There are a lack of mounting points for larger brakes, probes, or fairings.
Some of these limitations can be overcome with aftermarket parts: a longer deck for more space, a titanium steering column, and CNC-machined arms for increased rigidity. Our guide on the extended deck shows how far you can go with a Dualtron. When all these limitations add up, a custom build becomes more logical than simply adding together various modifications.
What a chassis includes:
- The deck: This is the platform that holds the battery and electronics, and to which all other components are attached. It can be made of aluminum or carbon fiber, depending on the intended use.
- The steering column: It fixes the steering angle and the height of the handlebars. See our guide on the titanium steering column.
- The front forks and suspension: They determine the suspension travel, wheelbase, and how the wheel follows the ground.
- Components: brake calipers, controllers, display, fairing.
How is a custom chassis designed?
Starting with the components
You don't design a chassis in a vacuum. You start with the components: the dimensions of the battery, the size and cooling requirements of the controllers, the width of the motors, the diameter of the discs, and the size of the calipers. The chassis is then designed to house all of these components as compactly as possible, with provisions for cable routing.
Start with the rider and their intended use
The rider's size determines the length of the deck and the height of the handlebars. The intended use dictates the geometry: a track scooter prioritizes precision in corners and stability during braking; a record-breaking scooter prioritizes stability in a straight line at very high speeds. Our guide on adjusting the geometry for track use details these concepts.
Validate before manufacturing
A chassis is first validated on paper, then assembled in a "mock-up" state, meaning assembled but not fully finished, to verify that each part fits correctly, that the cables are routed properly, and that the suspension moves freely.
What the RM-X has taught us
The RM-X is Rage Mechanics' performance scooter. Its chassis, like its motor, was designed and manufactured in our workshop in Lyon, and was conceived from the beginning with the other components in mind. With 50,000W, it has reached 173 km/h, measured on a track, setting a world record for speed in electric scooters.
The main takeaway can be summarized in one sentence: maximizing power output in such a compact vehicle requires that everything be designed as a cohesive unit. Before it, the SR-One, which was originally part of a Nami Burn-E, had already been completely redesigned for racing: the shocks were lowered and modified, and a much shorter titanium strut was used to achieve a more aggressive riding position when entering turns.
Our extended battery enclosure, measuring 670 mm, the same as the one used on the RM-X, also serves as the base for the Formula Escooter fairing.
Our custom chassis service
Notre prestation de châssis sur mesure suit trois étapes, décrites sur sa fiche :
- A discussion about usage, components (motors, batteries, controllers), and budget
- The design and validation of the plans will be done in collaboration with you
- The process includes manufacturing, bare assembly, and then either delivery or complete assembly.
For more specific needs, a custom enclosure for the battery, controller, or electronics may be sufficient. It can be manufactured using 3D printing or aluminum, depending on the requirements.
Workshop tip
Before starting on the chassis, finalize all the components. Changing the battery or controller after the plans have been approved often means having to redesign the deck. A successful chassis project begins with a fixed list of components.
Frequently Asked Questions
Is a custom-built chassis suitable for road use?
Machines in this category far exceed the 25 km/h speed limit allowed on public roads. They are intended for use on closed circuits, in competitions, and on private property.
Can I reuse any of the components from my current scooter?
Often, yes: motors, brakes, or batteries can be accepted for trade-in if their condition and performance warrant it. This is one of the points discussed during the initial consultation.
Aluminum or carbon fiber for the deck?
Aluminum is robust, repairable, and well-suited for machining. Carbon fiber is lighter, but requires more careful design and is less tolerant of localized impacts. The choice depends on the intended use and budget.
How long does it take to produce a custom chassis?
It depends on the project and the current workload of the workshop. The design and validation of the plans often take longer than the manufacturing process itself. Contact us to discuss your specific needs.